Simultaneous production of plurality of filament winding packages

ABSTRACT

Simultaneous production of a large number of winding packages of filaments of flat, round or profiled cross section by apparatus including extrusion devices, at least one cooling device, guide means, after-treatment devices (stretching, heating, etc.) and winding devices.

INTRODUCTION

In the production of profiled filaments in bundles by the extrusionprocess, hitherto it was the general practice to proceed from foils. Thethermoplastic material to be processed, for example a polyamide, apolyester, polyethylene or polypropylene, is melted in the extruder.Then it is, directly or by means of a metering pump, fed to theextrusion nozzle. Thereafter, whether as a cohesive foil or groups ofmore or less cohesive individual structures, the filaments are stretchedin common. Finally, after completion of longitudinal splitting intofilaments, the latter are wound individually or in bundles. Suchinstallations are already described, for example, in German Pat. Nos.667,234 and 746,593; British Pat. No. 1,035,657, French Pat. No.1,395,472, and Belgian Pat. No. 643,850. The disadvantage of such amanner of operation lies primarily in reoccurring productiondisruptions. For example, in the case of a so-called thread break or alapping in the stretching assembly, there are considerable time lossescaused by resetting or by stopping of the whole installation. There,furthermore, .[.there.]. is the drawback that this process is carriedout only with considerable expenditure in machinery and spacerequirement to separate completely the extruded foils or groups ofcohesive individual structures into individual filaments and then tosupply them individually to the further treatment or after-treatment,for example, twisting, crimping, or the like.

Correspondingly, there exists a general need to reduce the productiontime losses for such profile strand bundles of a polyamide, a polyester,polyethylene or polypropylene and the like and to improve the economy ofthe process, especially in the production of binding tapes, cords andprofile threads for technical and textile purposes and the like.

THE INVENTION

In order to satisfy these needs, the invention provides an annular orbeam-type spinning apparatus having a plurality of spinning nozzles, aswell as metering devices therefor, a cooling device or shaft for theextrusions, and also extrusion-deflection devices with the best possiblespace utilization for the large number of individual extrusions obtainedfrom a melt. The after-treatment devices, such as guide rollers,draw-off mechanisms, heating devices, stretching mechanisms and windingdevices are arranged contiguous to the devices serving for the extrusionof those structures. Each is allocated to certain, definite profilestrands or bundles of profile strands.

In such a system it is possible with use of air cooling to achieve anespecially compact type of construction, particularly if the coolingshaft is made so short that in it there occurs merely a solidificationof the profile strands sufficient for the further treatment. Dependingon the running speed of the strands, the shaft receives then only alength of 0.5 to 2 m. Directly at the discharge end of the shaft thereis arranged there a moistening device for the profile strands, whichprovides for the final cooling and simultaneous preparation of theribbon-type structures.

In certain cases it can be advantageous that all the profile strandsgenerated in such an installation have an equal running time betweentheir respective extrusions and their respective stretchings in theinstallation, independently of the distance between extrusion nozzle andstretching device. It is proposed, therefore, that between the partswhich are allocated to all or at least to a large number of strands, andthe subsequent parts, running times be provided by such dimensioningthat the length of all the running paths is approximately equalregardless of the arrangement and the relative places of theafter-treatment devices. These running time intervals are advantageouslyformed by corresponding deflection devices, over which the profilestrands are conducted in respective loops wherein, the nearer theafter-treatment devices are to the units common to all the profilestrands, the greater length is the loop.

The proposed single-stage installations make it expedient, for example,in the production of tying yarns, cords, thread or fiber bundles, toinclude still further devices, for example, twisting devices,texturizing devices or the like in the installation. This saves stillanother working operation in the production of strand-form orribbon-type structures. It has proved especially advantageous to arrangeafter the stretching mechanisms in each case a twist-winding device,preferably a ring-twist winding device. In a corresponding manner it canbe advantageous to arrange on outlet side of the stretching mechanisms atexturizing device, for example, curling mechanisms consisting of twogear wheels, a false-twist device or the like. Further, it iscontemplated to arrange the texturizing device, not after the laststretching roller, but between the two delivery mechanisms whichtogether form the stretching mechanism. Finally, it has proved favorableif the extrusion installation for the generation of bicomponent profileshas two extruders fed with different thermoplastic materials. With suchan installation it is possible to produce bicomponent profile strands,known in themselves, in which the generating of a crimping or curlingeffect is achieved directly, for example, by a corresponding selectionof the components.

DESCRIPTIONS OF THE DRAWINGS

The invention is explained in detail in the following with the aid ofthe appended drawing.

FIG. 1 is a schematic view of an installation according to the inventionfor the production of a large number of individually stretchedmonocomponent profile strands;

FIG. 2 is a schematic view of an installation corresponding to FIG. 1,in which, for the curling of the individually stretched profile strands,there is provided a gear wheel curling mechanism;

FIG. 3 represents a schematic view of an installation according to theinvention, in which at the outlet side of the individual stretchingmechanisms there is provided in each case a twist winding device; and

FIG. 4 is a schematic view of an alternative form of cooling shaft.

THE ILLUSTRATED EMBODIMENTS

In FIG. 1 there is represented, first of all, an extruder 1, whichserves for the melting of the thermoplastic to be extruded. The plasticis fed to the extruder via the filling funnel 2, and leaves it in amolten and possibly also degassed state through the discharge unit 3.The discharge unit 3 is connected by a melt line 4 with one or moreconveyance and metering pumps 5. Depending on the performance capacityof the extruder, it is possible to supply with one machine severalpumps, so that the formation of the melt line 4 and the number ofbranches will differ from case to case.

The conveyance and metering pumps 5 can in each case be connected over aspecial melt line 6 with the beam-type or annular nozzle unit 7. As arule, however, the pumps will be joined with the unit 7 allocated ineach case into one structural wall, so that the melt line 6 does notappear externally.

In the unit 7 there are arranged several nozzles in arbitraryarrangement, for example, in several rows next to one another. Thenozzles are supplied as uniformly as possible with melt, so that fromthem there emerge numerous individual extrusion profiles 8, 8a, 8b, 8c,etc. They are conducted through as short as possible a cooling shaft 9.The cooling shaft 9 consists in the simplest case of two parallel wallswhich have between them the extrusion melt paths. On one side of theshaft thus formed there is an air feed device 10, which can beconnected, for example, over a duct 11 with a blower (not represented).In this manner there is generated in the cooling shaft 9 an air streamwhich runs obliquely or approximately perpendicularly to the directionof travel of the profile strands. It withdraws from the still liquid orplastic profile strands such an amount of heat that they solidifysufficiently. By "sufficiently solidified" there is meant here such acooling that the strands no longer are in a thermoplastic state, eventhough they have not as yet been cooled to room temperature. Throughthis measure the cooling shaft 9 can in actual fact be kept very short,whereby the installation is of substantially lesser height thanheretofore used. Immediately below the shaft there is arranged amoistening device 12, through which the profile strands 8 are conductedin common and in which there is withdrawn their residual heat by contactwith the finishing fluid. Here they also are rendered supple for thesubsequent further treatment. The moistening device 12 consists, in aknown manner, of a roller or shaft 13, which, for example, can be madeof dull-chromed steel or of sintered ceramic material. The roller 13 canbe set in slow rotation by a mechanism not represented. It rotates withits lower part in a liquid trough 14, in which there is situated themoistening and finishing fluid. In order that the strand structuresrunning over the roller 13 come into contact with the roller surface,there are arranged, in a known manner, two contact pressure rollers orbars 15 and 16, which for example, can be made of steel orabrasion-proof ceramic material. The last contact pressure means 16 inrunning direction of the profile strands serves simultaneously for thedeflection for the bundle .[.8.]., whose individual profile strands arenow solidified to such a degree that they withstand without difficultythe deflection from the vertical into the horizontal. The strand bundleis then conducted over further deflection devices 17 and 18 and thensub-divided into suitable bundles of individual profile strands.

In the example of execution represented the endless ribbon-type profilestrands are first generated in a vertical downward direction and, aftersufficient cooling, are deflected with the aid of deflection devices 16,17 and 18 from the vertical into the horizontal and finally back intothe vertical. For practice of the invention it is not required thatexact use be made of this arrangement, It is in each case a question ofthe available space, whether the after-treatment devices are arranged inmore or less the same horizontal plane with the cooling shaft, or farabove or below. Depending on the space conditions present, there variescorrespondingly also the arrangement of the deflecting devicesmentioned.

The group of individual strands 8, 8a, 8b, 8c at first run in common andthen are fed to the deflecting devices 19-19c and 20-20c, through whichseveral or also in each case only individual profile strands 8 areseparated from the total group and supplied to the after-treatmentdevices 21. Another part 8a of the profile strands is separated out withthe aid of the deflecting device 19a and 20a and supplied to theafter-treatment device 21a. A further part 8b of the profile strands isseparated out by the deflecting device 19b and 20b and supplied to theafter-treatment device 21b, and finally a remaining part 8c is separatedout through the deflecting devices 19c and 20c and supplied to theafter-treatment device 21c. The deflecting devices belonging together ineach case are disposed at such a distance from one another that thetotal path lengths in all the strand trains of the system are equal orat least approximately equal.

In order to achieve a space-saving and at all times easily accessibleconstruction of the after-treatment devices, these are arrangedadjacently, preferably side-by-side. The individual after-treatmentdevices have to be constructed at a different distance from theproduction assembly. If the ribbon-type profile strands were directlysupplied to the after-treatment devices, then the path length andthereby the running time that the individual strand or the ground ofindividual strands undergoes in the after-treatment device 21 would beshorter than that in the other devices 21a, 21b, etc. In order tocompensate this, through the deflecting devices 19-19c and 20-20c, therehave been created running paths of substantially uniform lengths betweendeflection device 18 and devices 21-21c, which balance out thedifferences mentioned.

In the embodiment illustrated, the after-treatment devices 21-21c arestretching mechanisms. Each of the stretching mechanisms consists, inknown manner, of godets 22-22c and 23-23c, to which, in each case, theremay be allocated in addition a deflecting roller 24-24c and 25-25c. Theprofile strand to be treated is wound in each case, and, if need be,several times, around the godet 22-22c as well as its deflection rollerso that in this manner there is achieved an adequate friction. Theprofile strand is then conducted onward over a heating device 31-31c tothe godet 23-23c and also wound several times around it as well asaround the deflecting roller 25-25c. Finally the profile strands areconducted onward to the winding device 26-26c. The heating device is, inthe embodiment illustrated, an electrically heated stationary plate,whose side which is touched by the profile strands is slightly convexlycurved. Instead of the heating plate, however, there can be used otherheating devices in themselves known for this purpose.

FIG. 1 makes clear the advantages of the arrangement according to theinvention. Through the compact construction as well as the splitting upaccording to the invention of the entire profile bundle 8-8c into alarge number of adjacently arranged individual after-treatment pathsthere has been created a pronouncedly simple installation, whosecritical parts are easily accessible during the operation. Furthermore,there is also a further substantial advantage. Practical experience hasshown that thread breakages virtually never occur in the first part ofthe production process. It is not until the subsequent stretching thatsuch faults easily occur. If the latter should occur in the installationaccording to the invention, then it is no longer necessary largely tostop the entire installation, because in each case at most a singlestrand or bundle is affected by such a break. Since the correspondingparts of the device are readily accessible without disturbance of theadjacent devices, it is possible to remedy the fault without putting theother parts of the installation out of operation.

In FIG. 2 the numbering is carried out in the same manner as in FIG. 1.The parts correspond essentially to one another; there it is merelyshown that the after-treatment devices 21-21c can be followed by stillfurther treatment devices. In the example represented there is shown atwo-gearwheel curling device which is represented in each case at 27,27a, 27b and 27c. The arrangement of such after-treatment devices issubject to the well-known variations which are available to skilledworkers in the field. Thus, for example, it is possible to replace thegearwheel curling device represented in FIG. 2 by twisting devices, forexample, false-twist devices or other texturizing devices. Also it ispossible to provide the gearwheel arrangement between the two godets22-22c and 23-23c, respectively. Which of the variations coming inquestion is chosen is governed according to the nature of the materialto be worked, as well as according to the nature of the profile strandstructure which is to be generated in each case.

In FIG. 3 there is represented another form of execution of thearrangement according to the invention. In order to make it possible togenerate bicomponent strands, there are provided two extruders 1 and 1awith in each case separate filling hoppers 2 and 2a, as well ascorresponding melt-discharge units 3 and 3a for the moltenthermoplastic. The two extruder melt-discharge units are connected overlines 4 and 4a with separate pumps 5 and 5a and from there connectedover melt lines 6 and 6a with the common nozzle unit 7. Instead ofseparate conveyance and metering pumps 5 and 5a there can, of course, beused double pumps, as is known per se. In the interior of the nozzleunit 7 the two plastic streams are fed in a known manner to theprofile-forming nozzle openings and there united into a bicomponentstrand. The other parts shown in the drawing correspond to those of FIG.1, so that they are also provided with the same reference numbers.Following upon the stretching mechanisms 21-21c the monofile ormultifile ribbon formations are conducted to the guide eyes 32-32c, fromwhere they pass to ring-twist windings devices 28--28c, in themselvesknown. There they are twisted or twined in a known manner and wound intocops 29-29c.

The ring-twist winding devices are arranged in a known manner on acommon rail or bench 30, which can be moved up and down in rhythm--forexample hydraulically. These details of the device, however, are notrepresented in the drawing, since they are not per se the substance ofthe invention.

Merely by way of example, the strands 8-8c in the arrangement shown inFIG. 3 are conducted in each case directly from 18, i.e., withoutpath-length compensation via loop formation, to the rollers 20-20c ofthe after-treatment devices. Depending on the required uniformity andthe attainable quality, however, here, too, it is possible to use theloop formation represented in the embodiments of FIGS. 1 and 2, andconversely.

In order, if need be, to increase the cooling action on the freshlyextruded profile strands and thereby to be able to reduce the structurallength of the cooling shaft, it is further proposed that in addition tothe blowing cool air that a fine water mist be sprayed into the coolingshaft.

It can also be desired that the freshly extruded profile strands arecooled only to such an extent that they stick together at least inplaces, and then yield an irregular net-type structure. This can bedirectly achieved by corresponding shortening of the cooling shaft to,for example, 0.5 to 0.7 m in length.

Finally, the freshly generated profile strand bundle after passing thecooling shaft can also be deflected in such a way that, for the purposeof final fixing, it runs in opposite direction again through the coolingshaft. This is represented in FIG. 4, where the downwardly runningstrand bundle 8-8c is deflected at roller 32 and then is conducted backupward in the shaft 9 and exits over the roller 33.

The special advantage of the measures proposed according to theinvention are seen above all in the stretching units where the priorextremely space-consuming, troublesome section is subdivided intoconsiderably simpler individual units. These are combined with thefurther-processing devices in common units. Hereby, in the first place,there is achieved an extremely space-saving construction of the entireinstallation. In the second place there is the further advantage thatdisturbances unavoidable in the stretching process do not affect theoverall production, but rather only the individual part of theafter-treatment device is affected. These disturbances can be eliminatedwith the minimum expenditure in personnel.

It is thought that the invention and its numerous attendant advantageswill be fully understood from the foregoing description, and it isobvious that numerous changes may be made in the form, construction andarrangement of the several parts without departing from the spirit orscope of the invention, or sacrificing any of its attendant advantages,the forms herein disclosed being preferred embodiments for the purposeof illustrating the invention.

The invention is hereby claimed as follows:
 1. An arrangement for thesimultaneous production of a large number of endless bundled profilestrands of flat, round or profiled cross section of thermoplasticmaterials which comprises an extrusion press having an extrusion nozzleunit for simultaneously extruding a plurality of said profile strandsperpendicularly downwardly, a cooling shaft therebelow with means forrunning extruded strands downwardly .[.and then upwardly.]. through theshaft .Iadd.and then upwardly.Iaddend., said means including at leastone deflecting device for the deflecting of the downwardly running,cooled profile strands into the upward running direction, .[.at leastone further deflecting device for the deflecting of the profile strandsinto the approximately horizontal on a higher plane,.]. a space savingarrangement of a plurality of .[.said.]. after-treatment means with.Iadd.vertical .Iaddend.contiguous paths for individual strands orsub-groups of said strands, said .Iadd.after-treatment .Iaddend.meansincluding a large number of .[.adjacently arranged.]..Iadd.side-by-side.Iaddend., strand-processing units allocated in eachcase to a strand or bundle of profile strands, each of which unitsincludes at least a draw-off mechanism, a heating device, a stretchingmechanism, and a winding device .[.and .]. .Iadd.in vertically spacedrelationship to each other and providing the respective vertical,contiguous paths for said individual strands or sub-groups of saidstrands.Iaddend. , said after-treatment means and said winding devicesbeing positioned separate from but near the nozzle unit and cooling.[.device.]. .Iadd.shaft .Iaddend.for after-treating and windingindividual strands or sub-groups of strands extruded simultaneously fromsaid nozzle unit .Iadd.and a plurality of strand-deflecting means abovesaid strand-processing units for guiding said upwardly running profilestrands first into a horizontal plane above said units and then, asindividual strands or sub-groups of said strands, from said horizontalplanes into the respective vertical paths to said after-treatment means..Iaddend.
 2. An arrangement according to claim 1, characterized by astrand-cooling device which is a short cooling shaft having a lengthsufficient only to provide a partial solidification of the profilestrands, and a strand-moistening device at the outlet end of the coolingshaft for the further cooling and simultaneous finishing of the profilestrands.
 3. An arrangement according to claim 1, characterized bystrand-guide means providing path lengths for at least a large number ofstrands which are approximately equal between the strand-cooling deviceand the respective after-treatment devices.
 4. An arrangement accordingto claim 3, wherein said guide means comprises a plurality of deflectingdevices for the strands or strand bundles.
 5. An arrangement accordingto claim 1 characterized by a texturizing device at the exit end of thestretching mechanisms.
 6. An arrangement according to claim 1characterized by a ring-twist winding device at the outlet end of thestretching mechanisms.
 7. An arrangement according to claim 1,characterized by an extrusion press installation for the production ofbicomponent profile strands having two extruders adapted to be fed withdifferent thermoplastic materials, and melt-conveyor pumps therefor. 8.An arrangement according to claim 1 wherein said .[.a.]. cooling shafthas means for spraying water mist into the shaft. .Iadd.
 9. Anarrangement according to claim 1 wherein said first-mentioned meansembodies at least one deflecting device for deflecting said downwardlyrunning, cooled profile strands upwardly back into said cooling shaft,and said further deflecting device including deflecting means fordeflecting the upwardly running profile strands in said shaft laterallyoutwardly through an opening in the cooling shaft. .Iaddend..Iadd. 10.An arrangement according to claim 9 wherein said deflecting means ispositioned in said opening. .Iaddend. .Iadd.
 11. An arrangementaccording to claim 3 characterized by a texturizing device at the exitend of the stretching mechanisms. .Iaddend. .Iadd.
 12. An arrangementaccording to claim 3 characterized by a ring-twist winding device at theoutlet end of the stretching mechanisms. .Iaddend..Iadd.
 13. Anarrangement according to claim 3 wherein said cooling shaft has meansfor spraying water mist into the shaft. .Iaddend..Iadd.
 14. Anarrangement according to claim 3 wherein said first-mentioned meansembodies at least one deflecting device for deflecting said downwardlyrunning, cooled profile strands upwardly back into said cooling shaft,and said further deflecting device including deflecting means fordeflecting the upwardly running profile strands in said shaft laterallyoutwardly through an opening in the cooling shaft. .Iaddend..Iadd. 15.An arrangement according to claim 14 wherein said deflecting means ispositioned in said opening. .Iaddend. .Iadd.
 16. An arrangement for thesimultaneous production of a large number of endless bundled profilestrands of flat, round or profiled cross section of thermoplasticmaterials which comprises an extrusion press having an extrusion nozzleunit for simultaneously extruding a plurality of said profile strandsperpendicularly downwardly, a cooling shaft therebelow with means forrunning extruded strands downwardly through the shaft and then upwardly,said means including at least one deflecting device for the deflectingof the downwardly running, cooled profile strands into the upwardrunning direction, at least one further deflecting device for thedeflecting of the profile strands into the approximately horizontal on ahigher plane, a space saving arrangement of a plurality ofafter-treatment means with contiguous paths for individual strands orsub-groups of said strands, said after-treatment means including a largenumber of adjacently arranged, strand-processing units allocated in eachcase to a strand or bundle of profile strands, each of which unitsincludes at least a draw-off mechanism a heating device, a stretchingmechanism, and a winding device, and said after-treatment means and saidwinding devices being positioned separate from but near the nozzle unitand cooling shaft for after-treating and winding individual strands orsub-groups of strands extruded simultaneously from said nozzle unit andfurther characterized by strand-guide means providing path lengths forat least a large number of strands which are approximately equal betweenthe strand-cooling device and the respective after-treatment devices,said strand guide means embodying said aforementioned deflecting devicesand additional strand deflecting devices, said additional stranddeflecting devices embodying one strand deflecting member above each ofsaid strand-processing units and other strand deflecting devices fordeflecting respective individual strands or sub-groups of said strandsto the respective strand deflecting members above each strand processingunit, and said other strand deflecting devices being positioned toprovide equal path lengths for the respective individual strands or saidsub-groups of strands from said further deflecting device via theirrespective additional strand deflecting devices to their respectivestrand-processing units. .Iaddend. .Iadd.
 17. An installation for thecontinuous production and winding of synthetic, thermoplastic polymerfilaments which comprises a first part of said installation in which aplurality of said filaments are spun and solidified, said first partcomprising extrusion and nozzle means for extruding a plurality offilaments of a molten, synthetic, thermoplastic polymer, and coolingmeans to solidify the extruded filaments;a second part of saidinstallation adjacent said first part, said second part comprising aplurality of side-by-side filament treatment means, each treatment meanshaving filament-winding means preceded by first godet means and secondgodet means forming a filament stretching means; and filament guidemeans for conducting all of said filaments collectively from said firstpart to and along a common horizontal path above the plurality of saidtreatment means and then, as individual filaments or sub-groups offilaments, into separate paths of said individual filaments or saidsub-groups thereof running from said horizontal path to the respectivefirst godet means of said respective treatment means, and said filamentguide means embodying guide members spatially positioned to providesubstantially equal path lengths for the respective filaments betweensaid first part and their respective first godet means. .Iaddend.